Gas liquid contactor and method thereof

ABSTRACT

The invention relates to a gas liquid contactor and effluent cleaning system and method and more particularly to individually fed nozzle banks including an array of nozzles configured to produce uniformly spaced flat liquid jets shaped to minimize disruption from a gas. An embodiment of the invention is directed towards a gas liquid contactor having a plurality of modules including a liquid inlet and outlet and a gas inlet and outlet. An array of nozzles is in communication with the liquid inlet and the gas inlet. The array of nozzles is configured to produce uniformly spaced flat liquid jets shaped to minimize disruption from a gas flow and maximize gas flow and liquid flow interactions while rapidly replenishing the liquid.

This application is a continuation-in-part of U.S. patent applicationSer. No. 12/459,685, entitled “Gas Liquid Contactor and EffluentCleaning System and Method,” filed on Jul. 6, 2009, now U.S. Pat. No.7,866,638, which is a continuation-in-part of U.S. patent applicationSer. No. 12/012,568, entitled “Two Phase Reactor,” filed on Feb. 4,2008, now U.S. Pat. No. 7,871,063, which is a continuation of U.S.patent application Ser. No. 11/057,539, entitled “Two Phase Reactor,”filed on Feb. 14, 2005, now U.S. Pat. No. 7,379,487; this applicationalso claims the benefit of U.S. Provisional Application No. 61/100,564,entitled “System for Gaseous Pollutant Removal,” filed on Sep. 26, 2008,U.S. Provisional Application No. 61/100,606, entitled “Liquid-GasContactor System and Method,” filed on Sep. 26, 2008, and U.S.Provisional Application No. 61/100,591, entitled “Liquid-Gas Contactorand Effluent Cleaning System and Method,” filed on Sep. 26, 2008; all ofwhich are herein incorporated by reference as if set forth in theirentireties.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a gas liquid contactor and effluent cleaningsystem and method and more particularly to an array of nozzlesconfigured to produce uniformly spaced flat liquid jets shaped tominimize disruption from a gas flow and maximize gas flow and liquidflow interactions while rapidly replenishing the liquid.

2. Discussion of the Related Art

The absorption of a gas into a liquid is a key process step in a varietyof gas liquid contacting systems. Gas liquid contactors, also known asgas liquid reactors, can be classified into surface and volume reactorswhere the interfacial surface area between the two phases is created atthe liquid surface and within the bulk liquid, respectively. There aremany examples of surface gas liquid reactors such as rotating disks andliquid jet contactors. Rotating disk generators are disks (rotors)partially immersed in a liquid and exposed to a stream of gas. A thinfilm of liquid solution is formed on the rotor surface and is in contactwith a co-current reagent gas stream. The disk is rotated to refresh theliquid reagent contact with the gas. In a volume gas liquid reactor, thegas phase is dispersed as small bubbles into the bulk liquid. The gasbubbles can be spherical or irregular in shape and are introduced intothe liquid by gas spargers. The bubbles can be mechanically agitated toincrease the mass transfer.

In many gas liquid contacting systems, the rate of gas transport to theliquid phase is controlled by the liquid phase mass transfercoefficient, k, the interfacial surface area, A, and the concentrationgradient, delta C, between the bulk fluid and the gas liquid interface.A practical form for the rate of gas absorption into the liquid is then:Φ=φα=k _(G) a(p−p _(i))=k _(L) a(C _(L) *−C _(L))where the variable is the rate of gas absorption per unit volume ofreactor (mole/(cm³s)); φ is the average rate of absorption per unitinterfacial area (mole/(cm²s)); a is the gas liquid interfacial area perunit volume (cm²/cm³, or cm⁻¹); p and p_(i) are the partial pressures(bar) of reagent gas in the bulk gas and at the interface, respectively;C_(L)* is the liquid side concentration (mole/cm³) that would be inequilibrium with the existing gas phase partial pressure, p_(i); C_(L)(mole/cm³) is the average concentration of dissolved gas in the bulkliquid; and kG (mole/(cm²*s*bar)) and k_(L) (cm/s) are gas side andliquid side mass transfer coefficients, respectively.

In the related art, there are many approaches to maximizing the masstransfer and specific surface area in gas contactor systems. Theprincipal approaches include gas-sparger, wetted wall jet, and spray oratomization. The choice of gas liquid contactor is dependent on reactionconditions including gas/liquid flow, mass transfer, and the nature ofthe chemical reaction. Table 1 summarizes various mass transferperformance features of some related art gas liquid reactors. Tooptimize the gas absorption rate, the parameters k_(L), a, and(C_(L)*−C_(L)) must be maximized. In many gas liquid reaction systemsthe solubility of the C_(L)* is very low and control of theconcentration gradient, therefore, is limited. Thus, the primaryparameters to consider in designing an efficient gas liquid flow reactorare mass transfer and the interfacial surface area to reactor volumeratio, which is also known as the specific surface area.

TABLE 1 COMPARISON OF CONVENTIONAL GAS LIQUID REACTOR PERFORMANCE β (%,gas liquid k_(G) volumetric flow (mole/cm²s k_(L) a k_(L)a Reactor Typerate ratio) atm) × 10⁴ (cm/s) × 10² (cm⁻¹) (s⁻¹) × 10² Packed Column 2-25 0.03-2  0.4-2   0.1-3.5 0.04-7.0 (counter-current) Bubble Reactors60-98 0.5-2 1-4 0.5-6   0.5-24 Spray Columns  2-20 0.5-2 0.7-1.5 0.1-1  0.07-1.5 Plate Column 10-95 0.5-6  1-20 1-2   1-40 (Sieve Plate)There are various gas liquid contacting reactors whose performance isdependent on interfacial contact area. For example, the chemical oxygeniodine laser (COIL) produces laser energy from a chemical fuelconsisting of chlorine gas (Cl₂) and basic hydrogen peroxide (BHP). Theproduct of this reaction is singlet delta oxygen, which powers the COIL.The present technology uses circular jets of liquid BHP mixed with Cl₂gas to produce the singlet delta oxygen. In a typical generator, thejets are on the order of 350 microns in diameter or smaller. To generatethe jets, the liquid BHP is pushed under pressure through a nozzle platecontaining a high density of holes. This produces a high interfacialsurface area for contacting the Cl₂ gas. The higher the surface area,the smaller the generator will be and the higher the yield of excitedoxygen that can be delivered to the laser cavity. Smaller and moredensely packed jets improve the specific surface area, but are prone toclogging and breakup. Clogging is a serious problem since the reactionbetween chlorine and basic hydrogen peroxide produces chlorine salts ofthe alkali metal hydroxide used to make the basic hydrogen peroxide.Clogging also limits the molarity range of the basic hydrogen peroxide,which reduces singlet oxygen yield and laser power. The heaviest elementof the COIL system is this chemical fuel. Problems inherent in producingthe fuel increase the weight and decrease the efficiency of the COILlaser as a whole. Thus, there exists a need for a COIL laser that hasincreased efficiency and lower weight than present designs.

In another example, gas liquid contactors are also used in aerobicfermentation processes. Oxygen is one of the most important reagents inaerobic fermentation. Its solubility in aqueous solutions is low but itsdemand is high to sustain culture growth. Commercial fermenters (>10,000L) use agitated bubble dispersion to enhance the volumetric masstransfer coefficient k_(La). The agitation helps move dissolved oxygenthrough the bulk fluid, breaks up bubble coalescence, and reduces theboundary layer surrounding the bubbles. The interfacial area in thesesystems is increased by increasing the number of bubbles in the reactorand reducing the size of the bubble diameter. However, oxygen masstransfer to the microorganism is still constrained by the relativelysmall interfacial surface area of the bubble and the short bubbleresidence times. Current sparger systems (bubble dispersion) show arelatively small volumetric mass transfer coefficient k_(La) (about0.2/s); therefore, a new approach for generating maximum interfacialsurface area is desired to overcome these mass transfer limitations.

In designing systems for industrial applications, consideration must begiven to both cost and efficiency. Conventional wisdom generallyprecludes that both can be optimally obtained simultaneously. In thecase of gas liquid contactors, the conventional wisdom is generallymaintained in industrial applications such as chemical processing,industrial biological applications, pollution control, or similarprocesses requiring reacting or dissolving a gas phase chemistry with aliquid phase in a dynamic flow system.

In the example of pollution control, the standard methodology ofremoving a target compound or compounds in a wet process is acountercurrent flow system utilizing fine droplets of liquid phasefalling through a flowing gas phase 180ÿ in an opposite direction.Normally, gravity is used to draw the liquid phase to a capture sump atthe base of a column or tower. The gas phase flows up through the samecolumn or tower. This gas phase is then captured for further processingor released to the atmosphere.

In order to accommodate for larger scale chemical processes, the columnor tower must be scaled linearly with the size of the desired processeither by length or diameter. The current logical methodology is toincrease the scale of a single unit process since capital costs of asingle unit process generally do not scale linearly with size.

Another downside of standard countercurrent, gravitational oraerosol/droplet gas liquid contactors is that gas flows must be at a lowenough velocity such that gravity effects are greater than the buoyancyof the droplets. Regardless, significant evaporation of the liquidreactant generally does occur since contact times are long, requiringsignificant capture of that vapor prior to secondary processing orrelease.

SUMMARY OF THE INVENTION

Accordingly, the invention is directed to a gas liquid contactor andeffluent cleaning system and method that substantially obviates one ormore of the problems due to limitations and disadvantages of the relatedart.

An advantage of the invention is to provide large volumetric masstransport coefficients and resultant small size, low pressure sorbentoperation requiring minimal pumping capability across the system.

Another advantage of the invention is to provide a gas liquid contactorwith a reduced system footprint as compared to the related art.

Yet another advantage of the invention is to provide a gas liquidcontactor with a module design.

Still another advantage of the invention is to provide a gas liquidcontactor that uses enhanced specific surface area of a flat jet (e.g.,thin flat liquid jet) to improve the performance of gas liquid reactors.

Another advantage of the invention is to provide a modular system that,due to its smaller size, footprint, factory build, and high contactarea, has a fractional cost and site impact and potentially higherquality and unit to unit consistency as compared to conventional systemsfor the same reaction or scrubbing capacity.

Additional features and advantages of the invention will be set forth inthe description which follows, and in part will be apparent from thedescription, or may be learned by practice of the invention. Theobjectives and other advantages of the invention will be realized andattained by the structure particularly pointed out in the writtendescription and claims hereof as well as the appended drawings.

An embodiment of the invention is directed towards an apparatus. Theapparatus includes a chamber, a gas inlet and outlet coupled to thechamber, and a fluid plenum coupled to the chamber. The apparatus alsoincludes an individually fed nozzle bank. The nozzle bank includes anozzle array coupled to the liquid plenum. The nozzle array isconfigured to provide essentially planar liquid jets, each of the liquidjets include a planar sheet of liquid. The plurality of liquid jets alsolies in substantially parallel planes. The apparatus also includes a gasfluid separator coupled to the reaction chamber.

Still another embodiment of the invention is directed towards anindividual feed nozzle bank apparatus. The apparatus includes aplurality of nozzles configured to provide essentially planar liquidjets, the liquid jets comprising a planar sheet of liquid. The nozzlesalso lie in substantially parallel planes. A feed chamber is coupled tothe plurality of nozzles and at least one inlet is coupled to the feedchannel.

Yet another embodiment of the invention is directed towards a method ofprocessing gas phase molecules with a gas liquid contactor. This methodincludes forming a plurality of essentially planar liquid jets with aplurality of individually fed nozzle banks including an array ofnozzles. The liquid jets include a planar sheet of liquid and arearranged in substantially parallel planes. Gas with reactive or solublegas phase molecules is provided to the gas liquid contactor. The processalso removes at least a portion of the gas phase molecules by a masstransfer interaction between the gas phase molecules and the liquidjets.

Still another embodiment of the invention is directed towards processinggas phase molecules with a gas liquid contactor. The method includesforming a plurality of essentially planar liquid jets with a pluralityof individually fed nozzle banks including an array of nozzles. Theliquid jets include a substantially planar sheet of liquid and theliquid includes an aqueous slurry. Gas with reactive or soluble gasphase molecules is provided to the gas liquid contactor. The processalso removes at least a portion of the gas phase molecules by a masstransfer interaction between the gas phase molecules and the liquidjets.

Yet another embodiment of the invention is directed towards a method ofprocessing gas phase molecules with a gas liquid contactor. The methodincludes forming a plurality of instable liquid jets. The instableliquid jets include a distribution of drops formed with a plurality ofindividually fed nozzle banks. Gas with reactive or soluble gas phasemolecules is provided to the gas liquid contactor. The process alsoremoves at least a portion of the gas phase molecules by a mass transferinteraction between the gas phase molecules and the distribution ofdrops.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory and areintended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a furtherunderstanding of the invention and are incorporated in and constitute apart of this specification, illustrate embodiments of the invention and,together with the description, serve to explain the principles of theinvention.

In the drawings:

FIG. 1 illustrates a cross-sectional perspective view of a counter flowapparatus according to an embodiment of the invention;

FIG. 2 illustrates a cross-sectional perspective view of a co-flowapparatus according to another embodiment of the invention;

FIG. 3A illustrates a perspective view of the nozzle apparatus of FIGS.1 and 2;

FIG. 3B illustrates an exploded perspective view of the nozzle apparatusof FIG. 3A;

FIG. 4A illustrates a perspective view of the nozzle bank of FIG. 3B;

FIG. 4B illustrates a cross-sectional view of the nozzle bank of FIG. 4Aalong line A to A′;

FIG. 5 illustrates a bottom view of the nozzle bank of FIG. 4A and FIG.6;

FIG. 6 illustrates a perspective view of an apparatus according to anembodiment of the invention;

FIG. 7A illustrates an apparatus according to Example 1;

FIG. 7B illustrates an exit side of a nozzle plate according to Example1;

FIG. 7C illustrates an entrance side of a nozzle plate according toExample 1;

FIG. 7D is a photograph of a front view of a jet according to Example 1;

FIG. 7E is a photograph of a side view of a jet according to Example 1;

FIG. 8A illustrates a system according to Example 2;

FIG. 8B illustrates a nozzle bank according to Example 2;

FIG. 9 is a photograph of a front view of jets according to Example 2;

FIG. 10A illustrates a cross-sectional perspective view of the channelinsert according to Example 3;

FIG. 10B illustrates a cross-sectional perspective view of a channelinsert of FIG. 10A taken along B to B′;

FIG. 11 is a photograph of a front view of jets according to Example 3;

FIG. 12A illustrates a perspective view of a nozzle bank according toExample 4;

FIG. 12B illustrates a cross-sectional perspective view of the nozzlebank in FIG. 12A;

FIG. 12C illustrates a bottom view of the nozzle bank in FIG. 12A;

FIG. 12D is a photograph of a front view of jets according to Example 4;

FIG. 13A illustrates a perspective view of an apparatus according toExample 5;

FIG. 13B illustrates a bottom view of the nozzle banks in FIG. 13A;

FIG. 13C is a photograph of a front view of jets according to Example 5;and

FIG. 13D is a photograph of a front view of jets according to Example 5.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

The invention relates to a gas liquid contactor and effluent cleaningsystem and method and more particularly to an array of nozzlesconfigured to produce uniformly spaced flat liquid jets shaped tominimize disruption from a gas. Moreover, various embodiments directlyprovide a plurality of small single unit processes, aggregated intomodules, which by their design overcome the shortcomings of conventionaldesigns. Modularizing single unit processes allows for small systemswhich may be scaled by simply multiplying the module by convenientintegers to accommodate the scale of the process.

An embodiment of the invention is directed to an apparatus, such as agas liquid contactor, distillation apparatus, absorber apparatus,scrubber apparatus, ejector apparatus, and the like. The apparatusincludes a chamber, a gas inlet coupled to the chamber, and a gas outletcoupled to the chamber. A fluid plenum is coupled to the reactionchamber. The apparatus may include nozzles as described in U.S. patentapplication Ser. No. 12/459,685, entitled “Gas Liquid Contactor andEffluent Cleaning System and Method,” filed on Jul. 6, 2009, which ishereby incorporated by reference as if fully set forth herein. A gasfluid separator is also coupled to the reaction chamber. The gas fluidseparator is configured to separate gas and fluid in the apparatus.

In another embodiment, the apparatus includes at least one individuallyfed nozzle bank. The individually fed nozzle bank includes a nozzlearray coupled to the liquid plenum, wherein the nozzle array isconfigured to provide essentially planar liquid jets. Each of the liquidjets includes a planar sheet of liquid and the plurality of liquid jetslies in substantially parallel planes.

In this embodiment, two or more individually fed nozzle banks may beused and positioned adjacent to each other. The nozzles in these nozzlebanks may be formed in a plurality of different configurations, e.g., ina staggered configuration, non-staggered configuration, nozzles having anon-uniform size configuration, e.g., different depth of cut. In onestaggered configuration a first row of nozzles of a first nozzle bank, asecond row of nozzles in a second nozzle bank and a third row of nozzlein a third nozzle bank, are arranged such that the second row of nozzlesis offset and positioned between the first and third row of nozzles.

The individually fed nozzle bank(s) include a nozzle array in fluidcommunication with the liquid plenum. The nozzle array is configured toprovide essentially planar liquid jets, the liquid jets are formed in asubstantially planar sheet of liquid and lie in substantially parallelplanes. The nozzles may be formed as described in U.S. patentapplication Ser. No. 12/459,685, entitled “Gas Liquid Contactor andEffluent Cleaning System and Method,” filed on Jul. 6, 2009, which ishereby incorporated by reference as if fully set forth herein. Theapparatus can be configured such that gas from the gas inlet flows inco-flow direction or counter flow direction.

In this embodiment, the fluid plenum includes a main feed channelcoupled to at least one side channel. The side channel is coupled to theindividually fed nozzle bank to provide fluid to the nozzle. The fluidmay be a liquid, gas, or combination thereof, and the liquid may includesolids, e.g., an aqueous slurry.

In a preferred embodiment, the individually fed nozzle bank includes afeed chamber coupled to a nozzle plate. The feed chamber includes afirst side wall coupled to the nozzle plate; a second side wall coupledto the nozzle plate and the first side wall; a third side wall coupledto the nozzle plate and the second side wall; and a fourth side wallcoupled to the nozzle plate, the third side wall and the first sidewall. The first, second, third, and fourth sidewalls and the nozzleplate form a chamber having an opening at an end opposite the nozzleplate. The opening is coupled to a feed tube configured to receivefluid. The coupling may be done by welding, such as tungsten inert gas(TIG) welding, laser welding and the like.

In a preferred embodiment, the feed chamber includes an insert. Theinsert includes a plurality of feed channels configured to provideindividual liquid flow to each nozzle in the nozzle plate. The feed tubehas an opening on at least one end and is coupled to at least one sidechannel of the plenum. The feed tube is coupled with an o-ring seal orby welding. The chamber has a thickness of at least about 1 cm. Thechamber has a height above the nozzle bank in a range from about 1 cm toabout 8 cm.

In a preferred embodiment, the nozzle plate includes a material having asubstantially U-shape, V-shape, or other geometric configuration. Thenozzles are elliptically shaped in a more preferred embodiment. In anembodiment, the elliptically shaped nozzles have a minor axis in therange from about 0.5 mm to about 1.5 mm and a major axis in the rangefrom about 0.75 mm to about 5 mm. In a preferred embodiment, theelliptically shaped nozzles have a minor axis in the range from about0.6 mm to about 1.0 mm and a major axis in a range from about 1.5 mm toabout 2.5 mm. The nozzles may be formed to have a depth of cut, such as0.054 inches, 0.056 inches, 0.058 inches and combinations thereof depthof cut as described with reference to U.S. patent application Ser. No.12/459,685, entitled “Gas Liquid Contactor and Effluent Cleaning Systemand Method,” filed on Jul. 6, 2009, which is hereby incorporated byreference as if fully set forth herein. In a preferred embodiment, thearray of nozzles include a plurality of nozzles with uniform spacingbetween the nozzles. At least one nozzle has a projected cross sectionalarea in a range from about 0.25 mm² to about 20 mm².

The nozzle bank and the flow chamber can be formed from a variety ofdifferent materials, e.g., copper, nickel, chrome, steel, aluminum,coated metals, and combinations thereof. In addition, the materials mayalso include structural polymers, polyimides, composites andcombinations thereof.

Another embodiment of the invention is directed towards a method ofprocessing gas phase molecules with a gas liquid contactor. The methodincludes forming a plurality of essentially planar liquid jets with aplurality of individually fed nozzle banks including an array ofnozzles. The liquid jets include a substantially planar sheet of liquidand are arranged in substantially parallel planes. A reactive or solublegas phase molecule is provided and at least a portion of the gas phasemolecule is removed by a mass transfer interaction between the gas phasemolecule and the liquid jets. In another embodiment, the liquid mayinclude an aqueous slurry. The aqueous slurry may include a solidconcentration in a range from about 0.2% (w/w) to about 30% (w/w). In apreferred embodiment, the aqueous solution includes a solidconcentration in a range from about 10% (w/w) to about 25% (w/w).

The gas phase molecule may include a plurality of different gas phasemolecules as described in U.S. patent application Ser. No. 12/459,685,entitled “Gas Liquid Contactor and Effluent Cleaning System and Method,”filed on Jul. 6, 2009, which is hereby incorporated by reference as iffully set forth herein. For example, the gas phase molecules may includeat least one of sulfur oxides, nitrogen oxides, carbon dioxide, ammonia,acid gases, amines, halogens, and oxygen. In a preferred embodiment, thegas phase molecules include carbon dioxide from a combustion process,such as a coal fired plant.

The liquid jet may include a sorbent fluid for sequestering contaminantsand/or other fluids as described in U.S. patent application Ser. No.12/459,685, entitled “Gas Liquid Contactor and Effluent Cleaning Systemand Method,” filed on Jul. 6, 2009, which is hereby incorporated byreference as if fully set forth herein. For example, the liquid jet mayinclude water, ammonia, ammonium salts, amines, alkanolamines, alkalisalts, alkaline earth salts, peroxides, hypochlorites and combinationsthereof. In a preferred embodiment, the liquid jet includes a calciumsalt solution and a magnesium salt solution. The liquid jet may includea seawater solution or brine solution.

In an embodiment, the mass transfer interaction includes a volumetricmass transfer coefficient in a range from about 1 sec⁻¹ to about 1500sec⁻¹. In a preferred embodiment, the mass transfer interactioncomprises a volumetric mass transfer coefficient in a range from about 5sec⁻¹ to about 150 sec⁻¹. In a more preferred embodiment, the masstransfer interaction comprises a volumetric mass transfer coefficient ina range from about 10 sec⁻¹ to about 100 sec⁻¹. The mass transferinteraction is described with reference to U.S. patent application Ser.No. 12/459,685, entitled “Gas Liquid Contactor and Effluent CleaningSystem and Method,” filed on Jul. 6, 2009, which is hereby incorporatedby reference as if fully set forth herein.

In an embodiment of the invention, the gas may be provided at a varietyof different flow rates, for example, at a volume ratio in a range fromabout 100 min⁻¹ to about 1000 min⁻¹. Also, the flow rate of fluid intothe apparatus may vary, e.g., from 2 psi to about 15 psi in a preferredembodiment. The flat liquid jets in the array have a velocity less than15 m/sec and more preferably a velocity in a range from about 5 m/sec toabout 15 m/sec.

In an embodiment of the invention, the flat liquid jets in the array mayhave width greater than about 1 cm, such as a width in a range fromabout 1 cm to about 15 cm in a preferred embodiment. The flat liquidjets can have a thickness in a range from about 10 μm to about 1000 μm,and more preferably a thickness in a range from about 10 μm to about 250μm, and even more preferably a thickness in a range from about 10 μm toabout 100 μm. The flat liquid jets can have a length in a range fromabout 5 cm to about 30 cm, and more preferably a length in a range fromabout 5 cm to about 20 cm. It is noted that not every jet needs to fallwithin the aforementioned ranges of thickness, width, and length.However, in a preferred embodiment, the jets have a substantiallyuniform width, length, and thickness.

Yet another embodiment of the invention is directed towards a method ofprocessing gas phase molecules with a gas liquid contactor. The methodincludes forming a plurality of instable liquid jets including adistribution of drops from individually fed nozzle banks including anarray of nozzles. The method includes providing gas with at least onereactive or soluble gas phase molecule and removing at least a portionof the gas phase molecules by a mass transfer interaction between thegas phase molecules and the distribution of drops.

In this embodiment, combining operating conditions, e.g., high plenumpressures with a tightly packed array of nozzles, leads to collisionsbetween jets that generate a distribution of drops. In a preferredembodiment, the distribution of drops is a dense and substantiallyuniform distribution. The droplet distribution includes a range ofdroplet sizes from about 50 microns to about 2 mm, and a range of liquidpartial volumes between 0.5% and 20%. As the plenum pressure increases,the velocity of the liquid feeding the nozzles increases; this resultsin competition for water, which leads to instabilities in the flat jets.The instabilities manifest themselves in the jets in at least two ways.First, there is a pulsing of the jets, both along the same axis of thewater flow and in the transverse axis (nozzle to nozzle competition).Jet pulsing results from high plenum flow rates and leads to competitionbetween adjacent nozzles such that the width of a jet may oscillate. Thecompetition can result in a varying of the flow rate for an individualnozzle leading to jet pulsing. Second, the development of the linearsheet instability that is present in these types of jets under optimalconditions is also accelerated.

In another embodiment of the invention, the spacing of the jets is suchthat pulsing, combined with the linear sheet instabilities from eachjet, results in collisions between neighboring jets, thereby forming adistribution of drops. These collisions lead to the generation of highvelocity, e.g., velocities in the range from about 5 m/s to about 10 m/sor greater. The high droplet velocity results from the initial highvelocity of the jets at the exit of the nozzles, e.g., velocities in therange from about 5 m/s to about 10 m/s or greater. The large dropletvelocity coupled with the droplet size distribution minimizes theeffects of external forces on the droplets, such as forces caused by agas flow or gravity, leaving the overall droplet momentum unchanged.Moreover, the droplet velocity is small enough to provide reactionenhancement due to increased surface area.

The droplet generator may be obtained by adjusting at least one of depthof cut (DOC) of the nozzle, nozzle to nozzle spacing, nozzle bank tonozzle bank spacing, operating plenum pressure; using enhancers thatdecrease surface tension and/or viscosity; and combinations thereof inorder amplify the natural jet instabilities. For example, as the depthof cut of the nozzle is decreased the operating pressure to obtain aninstability in the jet is reduced. Also, as the nozzle to nozzle spacingis decreased the operating pressure to obtain jet instability is alsoreduced. As the operating plenum pressure is increased the velocity ofthe jet is increased, and collisions lead to instability of the jets.Enhancers may also be used to decrease surface tension which tends towiden jets and therefore increase jet-jet collisions and amplify thenatural jet instabilities. Finally, enhancers that decrease viscositytend to increase the susceptibility of the fluid to being deformed jetsand therefore tend to amplify the natural jet instabilities.

In a preferred embodiment, a gas liquid contactor includes a nozzlearray having nozzles with a 0.052 DOC, nozzle to nozzle spacing of about2 mm, nozzle bank to nozzle bank spacing of about 2 cm, and no stabilityunit. The individual nozzles are further described with reference toU.S. patent application Ser. No. 12/459,685, entitled “Gas LiquidContactor and Effluent Cleaning System and Method,” filed on Jul. 6,2009, which is hereby incorporated by reference as if fully set forthherein. The gas liquid contactor is operated at a plenum pressure of 15psi or greater to produce instable jets that break up. Preferably, thegas liquid contactor operates at a plenum pressure in a range from about17 psi to about 75 psi and, more preferably, operates in a plenumpressure range of about 17 psi to about 30 psi.

In another preferred embodiment, a gas liquid contactor includes anozzle array having nozzles with a 0.054 DOC, nozzle to nozzle spacingof about 2 mm, nozzle bank to nozzle bank spacing of about 2 cm, and nostability unit. The nozzles are further described with reference to U.S.patent application Ser. No. 12/459,685, entitled “Gas Liquid Contactorand Effluent Cleaning System and Method,” filed on Jul. 6, 2009, whichis hereby incorporated by reference as if fully set forth herein. Thegas liquid contactor is operated at a plenum pressure of 13 psi orgreater to produce instable jets that break up. Preferably, the gasliquid contactor operates at a plenum pressure in a range from about 15psi to about 73 psi and, more preferably, operates in a plenum pressurerange of about 15 psi to about 28 psi.

In still another preferred embodiment, a gas liquid contactor includes anozzle array having nozzles with a 0.056 DOC, nozzle to nozzle spacingof about 2 mm, nozzle bank to nozzle bank spacing of about 2 cm, and nostability unit. The gas liquid contactor is operated at a plenumpressure of 11 psi or greater to produce instable jets that break up.Preferably, the gas liquid contactor operates at a plenum pressure in arange from about 11 psi to about 71 psi and, more preferably, operatesin a plenum pressure range of about 13 psi to about 26 psi.

As the DOC of the nozzle increases, i.e., the nozzle dimensions areincreased, the amount of plenum pressure required to produce instabilityin the jets decreases. This is due to the increased velocity of thefluid through the nozzles as the DOC increases or the nozzle sizeincreases.

Reference will now be made in detail to an embodiment of the presentinvention, an example of which is illustrated in the accompanyingdrawings.

FIG. 1 illustrates a cross-sectional perspective view of a counter flowapparatus according to an embodiment of the invention.

Referring to FIG. 1, the counter flow apparatus is generally depicted asreference number 100. In operation of the apparatus 100 gas flow isshown by reference number 102 and fluid flow is shown by referencenumber 104. A plurality of individually fed nozzle banks 106 arepositioned adjacent to each other. The individually fed nozzle banks 106include a nozzle array in fluid communication with a fluid plenum thatincludes a main feed channel 108 coupled to a first side channel 110 anda second side channel 112. The apparatus includes a chamber 114, a gasinlet 116, a gas outlet 118, a liquid inlet 120, and a liquid outlet122. The apparatus also includes a liquid gas separator (not shown) asdescribed with reference to U.S. patent application Ser. No. 12/459,685,entitled “Gas Liquid Contactor and Effluent Cleaning System and Method,”filed on Jul. 6, 2009, which is hereby incorporated by reference as iffully set forth herein. The individually fed nozzle banks are configuredto provide essentially planar liquid jets 124, each of the liquid jetsincluding a substantially planar sheet of liquid. The plurality ofliquid jets lies in substantially parallel planes.

FIG. 2 illustrates a cross-sectional perspective view of a co-flowapparatus according to an embodiment of the invention. Referring to FIG.2, the co-flow apparatus is generally depicted as reference number 200.In operation of the apparatus 200 gas flow is shown by reference number202 and fluid flow is shown by reference number 204. A plurality ofindividually fed nozzle banks 106 is positioned adjacent to each other.The individually fed nozzle banks 106 include a nozzle array in fluidcommunication with a fluid plenum that includes a main feed channel 108coupled to a first side channel 110 and a second side channel 112. Theapparatus includes a chamber 114, a gas inlet 208, a gas outlet, aliquid inlet 120, and a liquid outlet. The apparatus also includes aliquid gas separator (not shown) as described with reference to U.S.patent application Ser. No. 12/459,685, entitled “Gas Liquid Contactorand Effluent Cleaning System and Method,” filed on Jul. 6, 2009, whichis hereby incorporated by reference as if fully set forth herein. Theindividually fed nozzle banks are configured to provide essentiallyplanar liquid jets 206, each of the liquid jets including asubstantially planar sheet of liquid. The plurality of liquid jets liesin substantially parallel planes.

FIG. 3A illustrates a perspective view of a nozzle apparatus. FIG. 3Billustrates an exploded perspective view of the nozzle apparatus of FIG.3A. FIG. 4A illustrates a perspective view of a nozzle bank of FIG. 3B.FIG. 4B illustrates a cross-sectional view of the nozzle bank of FIG. 4Aalong line A to A′. FIG. 5 is a bottom view of the individually fednozzle bank of FIG. 4B.

Referring now to FIGS. 3A-5, the apparatus includes a plurality ofindividually fed nozzle banks 106 positioned adjacent to each other. Theindividually fed nozzle banks 106 include a nozzle array in fluidcommunication with a fluid plenum that includes a main feed channelcoupled 108 to a first side channel 110 and a second side channel 112.The individually fed nozzle banks 106 are coupled to the first sidechannel 110 and the second side channel 112 with a sealing mechanism126, such as an o-ring seal or other seal as known in the art. In thisembodiment, the first side channel 110 has an access plate 128 in orderto provide access to the first side channel for servicing the unit. Inaddition, the second side channel 112 also includes an access plate 130.The access plates (128, 130) are connected by an attachment mechanism,such as a screw, rivet, or the like. Of course, the access plates (128,130) may also be welded to their respective side channels. The firstside channel 110 and the second side channel 112 are coupled to the mainfeed channel 108 with an attachment mechanism at connection point 132,such as a screw, rivet, welding or the like. A sealing layer may be usedin all connection points as known in the art in order to prevent leaks,e.g., a malleable material. An attachment plate 134 may be used tocouple the apparatus to the reaction chamber.

Referring now to FIGS. 4A-5, the individually fed nozzle bank 106 wasformed with a stainless steel tube 142. The tube was cut in halflengthwise. Nozzles 140 were cut into the tube 142. The spacing 144 ofthe nozzles 140 may be in a range suitable for a desired application,e.g., a range from about 1 mm or greater, in a preferred embodimentabout 1 cm or greater. A plurality of nozzles was formed in the tube.The tube 142 was attached, e.g., welded, to plates 146, which in turnwere attached to a feed body 148, thereby forming a chamber. As thelength of the chamber increases, the stability of the nozzle anddirection flow of the nozzle increase as discussed in the Examples. Thedimensions of the chamber may be adjusted accordingly.

In addition, in this embodiment optional dividers may be utilized toprovide an improved jet performance. A divider 150 or a plurality ofdividers may be used. The divider 150 may be configured to provideseparate feed channels 152 as depicted in the cross sectional drawing ofthe nozzle bank in FIG. 4B. Referring now to FIGS. 5 and 6, it is shownthat a plurality of individually fed nozzle banks may be used. In thisembodiment, eight nozzle banks (106, 156, 158, 160, 162, 164, 166, 168)were assembled in an array. The array is configured to permit gas topass between the liquid jets from the individual nozzle array. Ofcourse, the number of individual nozzle banks may be adjusted up or downdepending on the scale of the apparatus and the desired gas flow andvelocity.

Also, in this embodiment nozzles of adjacent nozzle banks wereinterlaced. For example, the nozzles of nozzle bank 106 are offset fromthe nozzles in bank 156, and alternated in the array so that adjacentnozzle banks have interlaced flat jets. The space between adjacentnozzle banks (from centerline to centerline) is shown by referencenumber 155 and may be in a range from about 1.2 or greater. The spacebetween adjacent nozzles is depicted as reference number 144 and may bein a range from about 1 mm to about 10 mm. The space between nozzles ofadjacent nozzle banks is depicted as reference number 154 and may be ina range from about 0.5 mm to about 5 mm. Of course, a plurality ofdifferent configurations may be employed, such as varying the distancebetween adjacent nozzle banks in the array and varying the distancebetween nozzles. In a preferred embodiment, those distances are uniform.

EXAMPLES Example 1

In Example 1, a single jet test apparatus was utilized to illustrate howwater exits a nozzle under normal operating conditions. The apparatus isdescribed with reference to FIGS. 7A-7C.

Referring to FIGS. 7A-7C, the apparatus is generally depicted asreference number 700 and includes an operating chamber 702, a liquidinlet 704, a fluid exit 708, a gas inlet 713 and a gas exit 714. Thefluid exit 708 is connected to a recirculation loop and coupled to apump (not shown) and the fluid inlet 704. A pressure gauge (not shown)is mounted for measuring fluid pressure in a plenum 709 above a nozzleplate 712. The plenum is a sealed chamber formed above the plate 712 andhas dimensions of 226 mm wide by 28.5 mm tall by 20 mm deep. The nozzleplate 712 includes three nozzle banks 714, 716, and 718. In thisconfiguration each nozzle bank includes three nozzles. In particular,nozzle bank 716 includes a first nozzle 720, a second nozzle 722, and athird nozzle 724. Each nozzle is separated by a uniform distance—thedistance between the first nozzle 720 and the second nozzle 722 is 4 mm.The distance between the nozzle banks 714, 716, and 718 is uniform. Inthis Example, the distance between nozzle bank 714 and nozzle bank 716is about 5 cm.

Each nozzle (720, 722, 724) was formed by cutting a 0.056 inch depth ofcut (DOC) into a tube (not shown). The tube was then cut and laserwelded onto a plate thereby forming the plate of nozzle banks. The tubewas stainless steel material having a thickness of 0.90 mm. The nozzleplate was stainless steel material having a thickness of 4.72 mm. Eachnozzle is also formed to have a major and minor axis of 2.67 mm and 1.2min, respectively. In this Example, nozzle bank 714 and nozzle bank 718were plugged by filling them with a bead of wax, i.e., a high meltingpoint paraffin. In addition, in nozzle bank 716, nozzles 720 and 724were also filled with the same wax material, thereby leaving only onenozzle 722 operational. The plate 712 was then positioned in theapparatus 700 as shown in FIG. 7A. The liquid plenum 709 is arrangedabove the plate 712 and liquid is configured to flow substantiallyhorizontally across the plate 712. The area ratio between the opening ofthe nozzle 722 and the liquid plenum is about 1:350.

In operation, the liquid inlet 704 was used to provide tap water atambient conditions to the plenum 709. The pressure gauge had a readingof about 7 psi indicating pressure in the plenum 709. FIG. 7D is aphotograph of a face of a jet formed in Example 1. FIG. 7E is aphotograph of a side view of the jet formed in Example 1.

Now referring to FIGS. 7D and 7E, the water exits the nozzle 722 andforms a flat jet 725. The jet 725 is formed to a length of about 12 cm.This length is measured as indicated by reference number 726. The lengthof the jet is measured from the exit of the nozzle to where the jetrecombines at the bottom. As shown in section 728, linear sheetinstability begins and the jet begins to break up. The breakup length isthe point where the jet begins to break up. The stability of the jet isshown by reference number 730. The instability region is indicated byreference number 732 and becomes important when multiple jets are placedin close proximity as described herein.

Example 2

In Example 2, an array of jets was formed with the test stand apparatusof FIG. 8A. The system is generally depicted as reference number 800.The system 800 includes a fluid catch basin 802, a fluid pump 804, andtubing connecting the single nozzle bank 806. Fluid flowed in arecirculation manner from the catch basin 802 to the pump and though thenozzle bank 806 to produce flat jets 808 that were recaptured in thecatch basin. The tubing from the pump was tied just upstream of thenozzle bank to allow feeding from both sides of the nozzle bank. Apressure gauge 810 was placed on the fluid line at the tee to measurefluid pressure supplied to the nozzle bank.

FIG. 8B illustrates a nozzle bank used in Example 2. The nozzle bank isgenerally depicted as reference number 812. The nozzle bank 812 wasformed from an 8 inch long, 0.5 inch diameter stainless steel tube. A 4inch middle portion 814 of the tube was compressed to form a 0.375 inchwide ellipse. The nozzle bank included nozzles 816. In this Example,thirty-two nozzles were cut into the tube via wire electrical dischargemachining (EDM). Each nozzle 816 was separated by a uniform distance ofabout 2 mm. For this Example, every other nozzle was taped off, suchthat sixteen nozzles were utilized and each nozzle was separated by 4mm.

FIG. 9 is a photograph of jets formed in Example 2.

Referring to FIG. 9, in operation of the apparatus in Example 2, 100%(w/w) ethylene glycol was flowed through the nozzle bank at ambienttemperature. The pressure gauge 810 had a reading of about 11 psiindicating the nozzle bank pressure. As shown in FIG. 9, the inner jetsconverged at a distance of about 5 cm from the nozzle bank 812, asindicated by the 1 cm grid scale to the left of the nozzle bank 812. Theouter jets converged at about 20 cm from the nozzle bank 812. Theconvergence of the jets in this Example is problematic with theplacement of the nozzle bank in an interlaced array. Also, there waslimited surface area of the jets due to the convergence.

Example 3

In Example 3, an array of jets was formed with the test stand apparatusof Example 2. For this Example, the nozzle bank 812 was modified with achannel insert as shown in FIGS. 10A-10B.

FIG. 10A illustrates a cross-sectional perspective view of a channelinsert according to Example 3. FIG. 10B illustrates a cross-sectionalperspective view of a channel insert of FIG. 10A taken along line B toB′.

Referring to FIGS. 10A-10B, the channel insert is generally depicted asreference number 1000. The channel insert 1000 was fastened to an insidewall of the nozzle bank 812 by set screws (not shown) through theopposing nozzle bank wall. The channel insert 1000 was formed from analuminum block. A plurality of channels 1002 were machined into theblock to match the corresponding nozzle openings in the nozzle bank 812.The individual channels 1002 in the insert were formed to be about 0.039inches in width, about 0.175 inches in length, and about 0.19 inches indepth. The edges of the insert were beveled to facilitate fluid flowthrough the nozzle bank, and one side was rounded to match the insidegeometry of the tube. In this Example, 5 nozzles were utilized withremaining nozzles blocked by tape. The spacing between nozzles was 4 mm.

FIG. 11 is a photograph of jets formed in Example 3.

Referring to FIG. 11, in operation of the apparatus in Example 3, 100%(w/w) ethylene glycol was flowed through the nozzle bank at ambienttemperature with the channel insert 1000. The pressure gauge again read11 psi, indicating the pressure of the nozzle bank. As shown, parallelflat jets 1100 were produced. The stable region of the flat jets wasnominally 15 cm. Below the stable region, the jets would fray andinteract with each other. The stability of the jets in this case wouldallow interlacing of the jets.

Example 4

In Example 4, an array of flat jets was made with the system asdescribed in Example 2. The nozzle bank was different and is describedwith reference to FIG. 12A-12C. The nozzle bank is generally depicted asreference number 1200. The nozzle bank 1200 was formed with a 0.25 inchdiameter stainless steel tube. The tube had a length of 10 cm and wascut in half lengthwise. Nozzles 1202 were cut into the tube 1204 usingwire EDM as described. The spacing 1203 of the nozzles was about 0.6 cmalong the tube as shown in FIG. 12C. Sixteen nozzles were formed in thetube. The tube was welded to stainless steel plates 1206, which in turnwere welded to a machined stainless steel feed body 1208 to form achamber. The distance from the centerline of the feed tubes to thenozzle tube was about 4 cm. The width of the chamber at the top of thefeed tube was 1.016 cm, and tapered to the width of the 0.25 inch nozzletube. Stainless steel dividers 1210 were welded inside the nozzle bank1200. Each nozzle 1402 had a separate feed channel 1212 as depicted inthe cross sectional drawing of the nozzle bank in FIG. 8B. The height ofeach channel in this nozzle bank was about 1.21 inches, and the dividers1210 were spaced at about 0.201 inches apart.

FIG. 12D is a photograph of jets formed in Example 4.

Referring to FIG. 12D, in operation of the apparatus in Example 4, 100%(w/w) ethylene glycol was flowed through the nozzle bank at ambienttemperature. The pressure gauge again read 11 psi, indicating thepressure of the nozzle bank. As shown, substantially parallel flat jetswere produced. The stable region of the flat jets was nominally 15 cm.Below the stable region, the jets would fray and interact with eachother. The stability of the jets in this case allows interlacing of thejets.

In addition, another run was performed in this Example. In this run anozzle bank without dividers 1210 was used. That is, in this setup thenozzle bank was identical to this Example, but did not include dividers1210. It was observed that the minimum height of the nozzle bank toproduce parallel jets was 5 cm; at heights less than 5 cm the flat jetswould converge as seen in Example 2.

Nozzle bank heights from 5 to 8 cm were also tested, that is, a distancefrom about 5 cm to about 8 cm from the centerline of the feed tubes tothe nozzle tube, with no internal dividers 1210. It was observed thatjets formed with a nozzle bank at 6 cm were slightly more parallel thanthe jets formed with a 5 cm nozzle bank height. In addition, there wasno noticeable improvement in jets formed (in parallelism of the jets)with nozzle bank heights above 6 cm.

Example 5

In Example 5, a jet test apparatus was utilized to illustrate how waterexits a nozzle bank array and interacts with nitrogen gas flowing in acounter flow configuration. The apparatus included an operating chamber,a fluid plenum, a gas inlet, a gas outlet, a liquid inlet coupled to thefluid plenum and a liquid outlet similar to the apparatus shown in FIG.1.

However, in this Example, seven nozzle banks (1302, 1304, 1306, 1308,1310, 1312, 1314) were assembled in an array as shown in FIG. 13A toallow gas to pass between the individual nozzle banks. The individualnozzle banks were those described in Example 4. Referring to FIG. 13A, aliquid plenum included a first feed plenum 1316 and a second feed plenum1318 coupled to a support member 1320 for two of the feed banks. In thisExample, the nozzle banks were fabricated with a plurality of nozzles1322 in each nozzle bank. Referring to FIG. 13B, the nozzles in bank1302 are offset from the nozzles in bank in 1304, and alternated in thearray so that adjacent nozzle banks had interleaved flat jets as shownin FIG. 13B. The space between adjacent nozzle banks (from centerline tocenterline) is shown by reference number 1324 and in this Example was12.5 mm. The space between adjacent nozzles is depicted as referencenumber 1326 and in this Example is 6 mm. The space between nozzles inadjacent nozzle banks is depicted as reference number 1328 and in thisExample is 3 mm.

The nozzle banks are mounted in a feed plenum that consists of two sideplenums (1316 and 1318) feeding the nozzle banks. The side plenums aremachined from stainless steel and contain removable acrylic windows forobservation and nozzle bank cleaning. The nozzle banks are o-ring sealed1330 into the side plenums. The nozzle banks and side plenums areattached to a single stainless steel feed tube (not shown). Stainlesssteel flanges are attached to the plenum assembly to allow mounting tothe reactor.

FIG. 13C is a photograph of jets formed in Example 5. FIG. 13D isanother photograph of jets formed in Example 5.

Referring to FIGS. 13C and 13D in operation, water was flowed throughthe nozzle bank array to produce an array of flat, interlaced jets. Apressure gauge on the fluid plenum measured 11 psi supplied to thenozzle banks. FIG. 13C shows the jets operating under a vacuumenvironment with no counter flow. Gas was introduced at the bottom ofthe reactor enclosure, and flowed counter to the jet flow and out of thereactor between the nozzle banks. FIG. 13D shows the jets operating withnitrogen gas counter flow at 100 Torr and 13 m/s. It was observed thatthe jets in this array were very stable operating either into ambientatmosphere or vacuum conditions. When the above counter flow wasintroduced to the jets, very little difference was seen in jet behavior.The flat surface at the top of the jet remained under counter flow. Thejets did not interact or coalesce, from vacuum to the above stated flow.

It will be apparent to those skilled in the art that variousmodifications and variations can be made in the present inventionwithout departing from the spirit or scope of the invention. Thus, it isintended that the present invention cover the modifications andvariations of this invention provided they come within the scope of theappended claims and their equivalents.

1. An apparatus, comprising: a reaction chamber; a gas inlet coupled to the reaction chamber; a gas outlet coupled to the reaction chamber; a fluid plenum coupled to the reaction chamber; an individual nozzle bank comprising a nozzle array coupled to the fluid plenum, wherein the nozzle array is configured to provide essentially planar liquid jets, each of said liquid jets comprising a planar sheet of liquid, said plurality of liquid jets lying in substantially parallel planes; and a gas fluid separator coupled to the reaction chamber.
 2. The apparatus of claim 1, wherein the fluid plenum comprises a main feed channel coupled to at least one side channel, wherein the at least one side channel is coupled to the nozzle bank.
 3. The apparatus of claim 1, further comprising a plurality of individual nozzle banks.
 4. The apparatus of claim 1, wherein the individual nozzle bank comprises: a feed body; a feed chamber coupled to the feed body, wherein the feed chamber comprises: a first side wall coupled to the feed body; a second side wall coupled to the feed body and the first side wall; a third side wall coupled to the feed body and the second side wall; and a fourth side wall coupled to the feed body, the third side wall and the first side wall.
 5. The apparatus of claim 4, wherein the feed chamber further comprises an insert.
 6. The apparatus of claim 4, wherein the feed chamber further comprises a plurality of feed channels configured to provide individual liquid flow to each nozzle in the nozzle array.
 7. The apparatus of claim 4, wherein the feed chamber has a thickness in a range of about 1 cm or greater.
 8. The apparatus of claim 4, wherein the feed chamber has a height above the nozzle bank in a range from about 1 cm to about 8 cm.
 9. The apparatus of claim 4, wherein the feed body has an opening on at least one end and is coupled to at least one side channel.
 10. The apparatus of claim 9, wherein the feed body is coupled to the at least one side channel with an o-ring seal or weld.
 11. The apparatus of claim 2, wherein the at least one side channel comprises a first side channel and a second side channel.
 12. The apparatus of claim 9, wherein the at least one side channel comprises a first and second side channel, wherein the first side channel is coupled to a first end of the feed body and the second side channel is coupled to a second end of the feed body.
 13. The apparatus of claim 1, wherein at least one nozzle in the nozzle array comprises elliptically shaped nozzles.
 14. The apparatus of claim 13, wherein the elliptically shaped nozzle has a minor axis in a range from about 0.5 mm to about 1.5 mm and a major axis in a range from about 0.75 mm to about 5 mm.
 15. The apparatus of claim 13, wherein the elliptically shaped nozzle has a minor axis in a range from about 0.6 mm to about 1.0 mm and a major axis in a range from about 1.5 mm to about 2.5 mm.
 16. The apparatus of claim 13, wherein the elliptically shaped nozzle has a depth of cut selected from the group consisting of 0.054 inches, 0.056 inches, 0.058 inches and combinations thereof.
 17. The apparatus of claim 1, wherein the apparatus comprises a modular gas liquid contactor.
 18. The apparatus of claim 1, wherein the nozzle array comprises a plurality of nozzles with uniform spacing between the nozzles.
 19. The apparatus of claim 1, wherein gas from the gas inlet is configured to flow in a co-flow direction.
 20. The apparatus of claim 1, wherein gas from the gas inlet is configured to flow in a counter flow direction.
 21. The apparatus of claim 1, wherein the apparatus is selected from the group consisting of a gas liquid contactor, a distillation unit, and a jet pump apparatus.
 22. The apparatus of claim 4, wherein the nozzle bank comprises a material selected from the group consisting of copper, nickel, chrome, steel, aluminum, coated metals, and combinations thereof.
 23. The apparatus of claim 1, wherein the nozzle bank comprises at least one of structural polymers, polyimides, composites and combinations thereof.
 24. The apparatus of claim 1, further comprising a plurality of individual nozzle banks, wherein each nozzle bank of the plurality of individual nozzle banks comprises an array of nozzles and wherein the nozzles of two adjacent nozzle banks are in a staggered configuration.
 25. The apparatus of claim 1, wherein the nozzle array comprises at least two nozzles separated by a distance greater than about 0.1 cm.
 26. The apparatus of claim 1, wherein the nozzle array comprises a single row of nozzles.
 27. The apparatus of claim 1, wherein the nozzle array comprises at least one nozzle having a projected cross sectional area in a range from about 0.25 mm² to about 20 mm².
 28. An individual nozzle bank apparatus, comprising: a plurality of nozzles configured to provide essentially planar liquid jets, each of said liquid jets comprising a planar sheet of liquid, said plurality of liquid jets lying in substantially parallel planes; a feed chamber coupled to the plurality of nozzles, wherein the feed chamber comprises a plurality of feed channels in respective communication with the plurality of nozzles; and at least one inlet coupled to the feed chamber.
 29. The apparatus of claim 28, wherein at least one of the plurality of nozzles comprises an elliptically shaped nozzle.
 30. The apparatus of claim 28, wherein the feed chamber comprises: a first side wall coupled to a feed body; a second side wall coupled to a feed body and the first side wall; a third side wall coupled to a feed body and the second side wall; and a fourth side wall coupled to the a feed body, the third side wall and the first side wall.
 31. The apparatus of claim 30, wherein at least one nozzle of the plurality of nozzles comprises an elliptical shaped nozzle having a minor axis in the range from about 0.5 mm to about 1.5 mm and a major axis in the range from about 0.75 mm to about 5 mm.
 32. The apparatus of claim 30, wherein the feed chamber has a thickness in a range from 1 cm or greater. 